Emergency Rescue Guide Manual

Contents

Introduction 1

Document Purpose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Vehicle Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Niro Identification 3

General Vehicle Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Identifying a Kia Niro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Niro Main Electronic Systems 6

Power Electronics Specification . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vehicle Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Airbag system (SRS: Supplemental Restraint System). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Emergency Procedures 12

Initial Response: Identify, Immobilize and Disable. . . . . . . . . . . .. . . . . . . . .. . . . . . . . . . . . . . . . 12

Extraction Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

NO-CUT ZONES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Vehicle Fire .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Submerged or Partially Submerged Vehicles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

High Voltage Battery Damage and Fluid Leaks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Roadside Assistance 23

Towing. . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Emergency Starting. . . . . . . . . . . . . . . . . . .. . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
 Introduction 1

Document Purpose

The purpose of this document is to familiarize first responders and the towing/roadside
assistance industry with the proper methods to handle the Niro in an emergency situation.
This guide gives a basic overview of key vehicle systems and instructions for dealing with
the different types of emergencies encountered by first responders. The emergency
response procedures for this vehicle will provide how to deal with the high voltage
electrical system.

Within this Emergency Response Guide you will find Notices, Cautions, Warnings
and Dangers which provide critical information and help you do your job safely and
efficiently. Below are the definitions of these terms. When you see a Notice, Caution,
Warning or Danger, be certain you understand the message before you attempt to
perform any part of an emergency response procedure.

A Danger alerts you to a hazardous situation which, if not avoided will

result in death or serious injury.

A Warning alerts you to a hazardous situation which, if not avoided, could result in death
or serious injury.

A Caution alerts you to a hazardous situation which, if not avoided, could result in minor or
moderate injury.

A Notice alerts you to a situation which, if not avoided, could result in vehicle damage.
 Introduction 2

Vehicle Description

As with other HEV, the Kia Niro uses the combination of a conventional gasoline
powered internal combustion engine and a high voltage electric motor to propel the
vehicle. This combination provides for improved gas mileage over a conventional Kia as
well as an increase in power over the standard 4-cylinder engine. The high voltage
electrical system is completely self-contained and does not need to be recharged by an
external power source such as a charging station. The high voltage battery is recharged
automatically while driving the vehicle. This is accomplished through the use of a generator
that produces electricity while driving and braking.
 Niro Identification 3

Identifying a Kia Niro

“Eco Hybrid” logo on tail gate
The Kia Niro can be easily identified by the “Eco Hybrid” logo attached on the tail gate.

Electrocution Risk
The hybrid logo can become hidden after a crash due to damage to the vehicle. Always be
sure to utilize additional methods of identification before determining the vehicle is not a
hybrid.

Engine Room
A “Hybrid” badge is also displayed under the hood on the engine cover. Also, the High
Voltage cabling is orange per SAE standard. Cables run from the bottom of the vehicle
where they connect the High Voltage Battery to the HPCU (Hybrid Power Control Unit),
Motor, Inverter, and other High Voltage components at the front of the vehicle.
The presence of orange cables under the hood identifies the vehicle as an HEV.

Hybrid
 Niro Identification 4

VIN Label

The VIN (Vehicle Identification Number) identifies the Hybrid with a “C” displayed in the
8th position, as shown in the below drawing.

The VIN can be found:

1) Underneath the front passenger seat (or driver seat).
2) On the vehicle certification label attached to the driver’s side (or passenger) center pillar.

XXXXXXXCXXXXXXXXX
8th position
 Niro Identification 5

Niro Cluster Instrument Panel

The Niro Cluster Instrument Panel displays the HEV specific features such as high voltage
battery SOC (State of Charge) in the highlighted part.

Avg. Fuel Efficiency

42.4 mpg
 Niro Main Electronic Systems 6

High Voltage System

Hybrid
Starter
Generator (HSG)

12V battery ground

Motor High-voltage battery

Transmission

Type Permanent magnet synchronous motor

Motor Max. Output HP(kW) 43 (32)

Max Torque lb-ft(Nm) 125 (170)

Inverter Input Voltage(V) 200 ~ 310

HPCU
LDC Max. Output HP(kW) 2.4 (1.8)

Type Lithium-ion polymer

Rated Voltage (V) 240

High Voltage
Battery Capacity (Ah) /
6.5 / 1.56
Energy (kWh)
Quantity for Pack
64Cells / 4Modules
(Cell / Module)
 Niro Main Electronic Systems 7

Vehicle components
12V auxiliary battery

The 12V auxiliary battery is unified with high voltage battery, which is located under the
rear seat, and powers all of the vehicle’s standard electronics like radio, air conditioner, etc.
Also, it powers the HPCU (Hybrid Power Control Unit) which controls high voltage current
to main electronic systems like the motor.
 Niro Main Electronic Systems 8

Motor

The motor of the HEV converts electrical energy into

motive force with a Max. power of 43Hp (32kW) and
Max. torque of 125lb-ft (170Nm).

Hybrid Power Control Unit (HPCU)

The HPCU includes an Inverter and LDC (Low Power

DC-DC Converter) in one housing. The inverter
converts DC to AC to supply electricity to the motor.
It also converts AC to DC to charge the high voltage
battery. The LDC transfers high voltage electricity to 12
voltage to charge 12V auxiliary battery.

Integrated Battery System (High

voltage and Low voltage)

The high voltage battery is integrated with the low voltage

battery. High voltage modules supply and store
electric energy to traction motor and it is a Lithium ion
polymer battery with specifications, 240V / 6.5Ah / 1.56kWh.
It is located in the under the rear seat of the Niro.

Hybrid Starter Generator (HSG)

The HSG restarts the engine at HEV mode and also

charges the high voltage battery while driving,
that is generator for hybrid vehicle.
 Niro Main Electronic Systems 9

High Voltage Orange Cabling

The High Voltage cabling is orange, per SAE standards. Cables run under the floor of the
vehicle and connect the High Voltage Battery to the HPCU, Motor, LDC, Inverter and other
High Voltage components at the front of the vehicle.
The presence of orange cables under the hood, on the under-floor battery compartment,
or orange shielding under the car, identifies the vehicle as a HEV.

High Voltage Cables

 Never cut or disconnect the high voltage orange cabling and connectors without first
disabling the system by removing the safety plug (located under rear seat-passenger
side).
 Exposed cables or wires may be visible inside or outside the vehicle. Never touch
the wires, cables, connecters, or any electric components before disabling the
system, to prevent injury or death due to electrical shock.

Failure to follow these instructions can lead to death by electrical shock.

High Voltage Cable

 Niro Main Electronic Systems 10

Airbag system (SRS: Supplemental Restraint System)

Airbag
Seven airbags are installed in the Niro, located in standard area of the vehicle so that the
first responder can find them immediately. Before emergency procedure, make sure the
vehicle ignition switch is turned off, disconnect the negative connector from the 12V
auxiliary battery (located behind the rear passenger seat-drivers side) to prevent accidental
deployment of undeployed airbags.

(1) Driver front airbag

(2) Passenger front airbag
(3) Side airbag
(4) Curtain airbag
(5) Driver’s knee air bag

❈ The actual air bags and seats in the vehicle may differ from the illustration.

Seat Belt Pretensioner

The Niro is equipped with driver’s and front passenger’s seat belts with pretensioners.
When the seat belt pretensioners are activated in a collision, a loud noise may be heard
and fine dust, which may appear to be smoke, may be visible in the passenger
compartment. These are normal operating conditions and are not hazardous. The seat belt
pretensioner assembly mechanisms may become hot during activation, and may need
several minutes to cool after they have been activated.
 Niro Main Electronic Systems 11

Airbag system components

1. Driver Airbag (DAB) 8. Front Impact Sensor (FIS)

2. Clock Spring 9. Knee Airbag (KAB)
3. Steering Wheel 10. Pressure Side Impact Sensor (PSIS)
4. Seat Belt Pretensioner (BPT) 11. Rear Side Impact Sensor (RSIS)
5. Passenger Airbag (PAB) 12. Supplemental Restraint System Control
6. Side Airbag (SAB) Module(SRSCM)
7. Curtain Airbag (CAB) 13. Emergency Fastening Device (EFD)
14. Occupant Classification System (OCS)

Undeployed Airbags

To avoid injuries caused by accidental deployment of undeployed airbags

 Do not cut the red colored part on the above layout.

 Make sure the vehicle ignition switch is turned off, disconnect the negative cable
from the 12V auxiliary battery (located behind the rear passenger seat-drivers
side), and wait 3 minutes or longer to allow the system to deactivate.

Failure to follow any of these instructions may result in serious injury or death from
accidental deployment of the airbag system.
 Emergency Procedures 12

Initial Response: Identify, Immobilize and Disable

The following procedures should be used whenever you are dealing with a Niro at an
emergency scene. All other operations should be consistent with your department’s
standard operating procedures or guides. When a Hybrid is damaged in a crash, the high
voltage safety systems may have compromised and present a potential high voltage
electrical shock hazard. Exercise caution and wear appropriate personal protective
equipment (PPE) safety gear, including high voltage safety gloves and boots. Remove all
metallic jewelry, including watches and rings.

Identify
The Niro is an Eco-electric vehicle. Emergency responders should respond to emergency
scenarios involving the Niro accordingly being careful to avoid contact with the high voltage
system within the vehicle.
 Emergency Procedures 13

Immobilize

The next step is to immobilize the vehicle to prevent any accidental movement that can
endanger response personnel and civilians alike. Although Niro emits virtual sound of
engine, if it is damaged in a crash, there may be instances where the vehicle appears to be
shut of when it is not due to no engine sound.
When in "READY" mode the lamp is illuminated on the Instrument Panel, the
vehicle can move almost silently using the electric motor. Responders should approach the
vehicle from the sides and stay away from the front or rear as they are potential paths of
travel. Immobilizing the vehicle in the following procedure.

Position the shift

Chock the wheels Set the parking brake.
lever in park (P)
 Emergency Procedures 14

Disable
The final step in the initial response process, conducted after immobilizing the vehicle, is to
disable the vehicle, its SRS components and the high voltage electrical system. To prevent
current flow through the system, use one of the following procedures to disable the vehicle.

I . Disabling the System – Smart Key System and “POWER” START/STOP Button

1. Confirm the status of the READY light on

the instrument panel. If the READY
light is illuminated, the vehicle is on.

a) If the READY light is NOT

illuminated, the vehicle is off. Do not
push the “POWER” START/STOP
button because the vehicle may start.
“POWER” START/STOP Button

b) To turn off the system, put the shift lever in the P (Park) position and press the
POWER button.

Without depressing the brake pedal

Pressing POWER button

Vehicle condition
POWER button LED color
Off Off
Electrical accessories are
One time Amber
operational.
The warning lights can be checked
Two times Reddish orange
before the vehicle is started.
Three times Off Off

While depressing the brake pedal while a shift lever is in the P (Park) position
Pressing POWER button
Vehicle condition
POWER button LED color
Off Off
One time Off Ready to drive
 Emergency Procedures 15

2. If necessary, lower the windows, unlock the doors and open the tail gate as required,
before disconnecting the 12V battery. Once the 12V battery is disconnected, power
controls will not operate.
3. Before disconnecting 12V battery, remove the Smart Key at least 2 meters away
from the vehicle to prevent accidental restart.

4. Use the following procedure to remove the safety plug

and disable the high voltage battery:
a) Open tail gate and remove the luggage b) Disconnect the battery negative connector (A).
side cover (A).

c) Remove the safety plug cover (A) d) Unfasten the hook (A)
under the rear seat. to the direction of arrow.

e) Unfasten the lever (A) to the f) Remove the safety plug (A).
direction of arrow.
 Emergency Procedures 16

II. Disabling the System – IG (Ignition) Fuse Removal

1. Open the hood.

2. Remove the engine room fuse box

cover.

3. If necessary, lower the windows,

unlock the doors and open the tail gate
as required, before disconnecting the
12V battery (located behind the rear
Engine room fuse box
passenger seat-drivers side). Once the
12V battery is disconnected, power
controls will not operate.

4. In the event the vehicle may not

be disabled using the “Power”
START/STOP Button, pull the IG1,
IG2 Fuse from the engine room fuse
box. If the IG Relay cannot be
located, pull out all the fuses and
relays in the fuse box.
 Emergency Procedures 17

5. Remove the safety plug and disable the high voltage battery
(Refer to No.5 procedure in page 15)

If previously mentioned methods of disabling system are unsuccessful, the vehicle is not
secured from accidental deployment of undeployed airbags and electric shock of high-
voltage components.

Electrocution Risk

 Before engaging in emergency response procedures, ensure the vehicle is disabled

and wait 5 minutes to allow the capacitor in the high voltage system to discharge
to avoid electrocution.
 Exposed cables or wires may be visible inside or outside the vehicle. Never touch
the wires or cables before disabling the system, to prevent injury or death due to
electrical shock.
Failure to follow these instructions can lead to death by electrocution.
 Emergency Procedures 18

Extraction Operations
The Niro is an Eco-electric model (HEV/PHEV). Because of the high voltage components
contained therein, first responders should pay special attention when they extract occupants
in the car. Before extraction operations, the first responders should "Identify, Immobilize and
Disable" the vehicle as discussed in sections on page 12-17.

Vehicle Stabilization

Use standard stabilization (cribbing) points,

as shown beside. Always be sure to connect
to a structural member of the vehicle and
avoid placing cribbing under high voltage
cables, fuel lines and other areas not
normally considered acceptable.

Extraction tools and procedure

When responding to an incident involving a Niro, we recommend that the first responders
follow their organization’s standard operating procedures for assessing and dealing with
vehicle emergencies.
When the first responders cut the vehicle, they should always pay special attention to the
airbag system, orange colored high voltage cables and other high voltage components so that
the parts are not damaged, causing risks of explosion.

Location of ultra-high strength steel

In the image, high strength steel is

used in the areas colored in blue and
ultra-high strength steel is used in the
red colored areas. Depending on the
tools used, ultra high strength steel
can be challenging or impossible to
cut. If necessary, use a workaround
Mild steel
technique.
High strength steel
Ultra-high strength steel
 Emergency Procedures 19

NO-CUT ZONES
The areas highlighted in yellow indicate “no-cut zones” that must not be cut during
emergency procedures due to high voltage, gas inflators and airbag hazards.

Do not attempt to enter the vehicle by cutting through the "no-cut zones" identified in the
image below. Cutting through these zones can result in death by explosion or
electrocution.

Airbag&Gas inflators Airbag Gas inflators

Ultra-high strength
Supplemental Restraint System Control
steel
Module (SRSCM)
High voltage battery & Fuel system 12V Battery
cable
Refrigerant gas pipe Gas Lifter
 Emergency Procedures 20

Vehicle Fire
After Initial Emergency Response Procedures have been applied, Firefighting Procedures may
begin. Kia recommends that each response team follow their own department’s standard
operating procedures for fighting vehicle fires in combination with the Niro HEV specific
details that are covered in this section.

Firefighting Operations
If the high-voltage battery pack is either involved in or at risk of being involved in a fire in a
Niro HEV, strict cautions must be taken while conducting firefighting operations due to
following reasons:
• Lithium-ion Polymer batteries contain gel electrolyte that can vent, ignite, and produce
sparks when subjected to temperatures above 300°F.
• May burn rapidly with a flare-burning effect.
• Even after the high-voltage battery fire appears to have been extinguished, renewed or
delayed fire can occur.
- Use a thermal imaging camera to ensure the high voltage battery is completely cooled
before leaving the incident.
- Always advise second responders that there is a risk of the battery re-igniting.
- Fire, submersion or a collision that has compromised the high voltage battery, always
store it in an open area with no exposures within 50 feet.
• A burning battery could release hydrogen fluoride, carbon monoxide, and carbon dioxide
gasses. Use NIOSH/MSHA approved full-face self-contained breathing apparatus (SCBA)
with full protective gear. Even if the high-voltage battery pack is not directly involved in a
vehicle fire, approach the vehicle very carefully.
Even if the high-voltage battery pack is not directly involved in a vehicle fire, approach the
vehicle very carefully.
 Emergency Procedures 21

Extinguishers
• Small fires that do not involve the high voltage battery should be extinguished using
an ABC fire extinguisher for an electrical fire.

• Do not attempt to extinguish fires that involve the high voltage battery with small
amounts of water as this can result in electrocution. Fires that involve the high
voltage battery should be extinguished using large amounts of water to cool the high
voltage battery. Fire fights should not hesitate to pour larger amounts of water on
the vehicle in such scenarios.

Submerged or Partially Submerged Vehicles

Some emergency responses can involve a submerged vehicle. Niro HEV that is
submerged does not have high-voltage component on the vehicle’s body or framework.
It is safe to touch the vehicle’s body or framework if there is no severe damage to the
vehicle, whether it is in water or on land.
In the event of the vehicle is submerged or partially submerged, remove the vehicle
from the water before attempting to disable the vehicle. Drain the water from the
vehicle. Use one of the methods described in page 14-19 to disable the vehicle.

 If severe damage causes high voltage components to become exposed, responders

should take appropriate precautions and wear appropriate insulated personal
protective equipment.
 Do not attempt to remove a safety plug while the vehicle is in water.

Failure to follow these instructions can lead to death or serious injury by electrocution.
 Emergency Procedures 22

High Voltage Battery Damage and Fluid Leaks

If electrolyte solution leakage, or damage such as any problem with the Lithium ion battery
casing are observed, the first responders should attempt to neutralize the battery by applying
a large volume of water to the battery pack while wearing appropriate Personal Protective
Equipment (PPE). The neutralization process helps stabilize the thermal condition of the
battery pack but does not discharge the battery.

• Cease all smoke, spark, flame around the vehicle.

• Electrolyte solution is a skin irritant.
• Do not touch or step on the spilled electrolyte.
• If electrolyte leak occurs, wear appropriate solvent resistant PPE and use soil, sand, or
a dry cloth to clean up the spilled electrolyte. Be sure to adequately ventilate the area.

Electrolyte Irritation

The high voltage battery contains electrolyte solution. To avoid exposure to electrolyte
solution and serious personal injury, always wear appropriate solvent resistant
PPE (Personal Protective Equipment) and SCBA (Self-Contained Breathing Apparatus).

 Electrolyte solution is an eye irritant – In the event of contact with eyes, rinse with
plenty of water for 15 minutes.
 Electrolyte solution is a skin irritant. Therefore, in the event of contact with skin,
wash off with a soap.
 Electrolyte liquid or fumes coming into contact with water will create vapors in the air
from oxidization. These vapors may irritate skin and eyes. In the event of contact
with vapors, rinse with plenty of water and consult a doctor immediately.
 Electrolyte fumes (when inhaled) can cause respiratory irritation and acute
intoxication. Inhale fresh air and wash mouth with water. Consult a doctor
immediately.
 Roadside Assistance 23

Towing
In the event of an accident, the high voltage system must be disabled. The safety plug must
be removed from the high voltage battery according to one of the methods described in
sections of page 17-20 to disable the vehicle.
Towing Niro Vehicle is not different from towing
a conventional FWD vehicle with the exception
that all wheels needs to be lifted off the road.
If emergency towing is necessary, we
recommend having it done by an authorized
Kia dealer or a commercial tow-truck service.
Proper lifting and towing procedures are
necessary to prevent damage to the vehicle.
The use of wheel dollies or flatbed is
recommended.

 Do not tow the vehicle backwards with

the front wheels on the ground as this
may cause damage to the vehicle.
 Do not tow with sling-type equipment.
Use wheel lift or flatbed equipment.
 Never tow the vehicle with the
rear/front wheels on the ground
(forward or backward), as this may
cause fire or damage to the motor.
 Roadside Assistance 24

Emergency Starting
Before Jump Starting

1. If the vehicle appears to have a dead

battery, first press the 12V Battery
Reset button (A). Then immediately
start the vehicle by pressing the brake
and turning the ignition on or pressing
the Engine Start/Stop button. A
2. If the vehicle does not start after
completing the above steps, then jump
start the vehicle (as described below).

Jump Starting

Do not attempt to jump start the high

voltage battery, it cannot be jump started.
In case of full discharge of the high voltage
battery, the vehicle must be towed as
mentioned on the previous page.
In case the 12V auxiliary battery is
discharged, connect a starting device to
the jump terminal in the engine room as
you would any 12V battery (see image).
Refer to “Emergency Starting” of Owner’s
Manual for additional information. Connect
jumper cables in numerical order and
disconnect in reverse order.

Electrocution Risk

Do not attempt to jump start the Niro high voltage battery.